Smart solenoid compound gun driver and automatic calibration method

ABSTRACT

A device for calibrating a spray gun and an associated method are provided. The spray gun has a nozzle that is opened and closed by moving an internal needle out of and into sealing engagement with the nozzle. A virtual position of the needle is tracked and recorded by the control system. The control system is recalibrated when the virtual position and the actual position of the needle do not correspond. The device includes a sensor structured to detect characteristics of the current used to power the solenoid, and to identify an anomaly in solenoid current characteristics associated with an actuator member seating against said solenoid. During calibration, the solenoid is placed in a calibration configuration and the identifiable anomaly is detected. When the identifiable anomaly is detected, the spray gun is returned to an initial configuration and the virtual needle position is reset.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation application and claims priority toU.S. patent application Ser. No. 14/307,915, filed Jun. 18, 2014,entitled “Smart Solenoid Compound gun Driver and Automatic CalibrationMethod,” which application is a continuation application and claimspriority from U.S. patent application Ser. No. 13/471,782, filed May 15,2012, (now U.S. Pat. No. 8,794,547, issued Aug. 5, 2014), entitled“Smart Solenoid Compound Gun Driver and Automatic Calibration Method.”

BACKGROUND OF THE INVENTION

1. Field of the Invention

The disclosed and claimed concept relates to a system utilizing anozzle, which is closed by an internal needle, structured to dispenseliquids and, more specifically, to a system for calibrating the needlelift relative to the nozzle body.

2. Background Information

Certain fluid dispensing systems are structured to dispense a liquidthat is less viscous when hot. If the liquid is allowed to cool, theviscosity increases making it more difficult to apply the liquid in acontrolled and/or consistent manner. Such liquid dispensing systems mayutilize nozzle assemblies, or “spray guns” that are closed by aninternal needle. The liquid may be a sealant or an adhesive. Theremainder of this description shall use an adhesive as an example, butit is understood that the liquid is not limited to an adhesive.Generally, an adhesive is either a solvent-based adhesive or awater-based adhesive. In some aspects, the spray gun is adapted to aspecific type of adhesive. For example, a solvent-based system willinclude a temperature control to maintain the temperature of the liquid.The spray gun includes a housing that defines a chamber with a nozzle.The chamber includes a liquid inlet and may contain a liquid outlet. Theliquid flows into the chamber via the liquid inlet. The liquid may bestored, briefly, in the chamber before application. For a water-basedadhesive, the liquid is, typically, expelled exclusively via the nozzle.For a solvent-based adhesive, a portion of the liquid may be dispensedvia the nozzle and any excess liquid that may be recycled exits thechamber via the outlet. The liquid may then be drained from the system,or, reheated and re-circulated. In this configuration, the liquid in thechamber may be maintained at a temperature that allows for a known,consistent flow rate. Typically, the liquids dispensed by such sprayguns must be maintained in a very limited temperature range while in thespray gun liquid chamber.

The nozzle defines an internal passage having a generally frusto-conicalshape, i.e., a frustum. The nozzle further includes an internal seat;the seat may be part of the internal surface of the nozzle. A needlehaving its longitudinal axis aligned with the axis of the nozzle passageis used to seal the passage. That is, the needle is coupled to anactuator structured to move the needle in an axial direction; i.e.,longitudinally. The needle proximal end is coupled to the actuator andthe opposite end of the needle, the needle distal tip, is shapedgenerally, or substantially, to correspond to the shape of the nozzleseat. When the needle is in a forward, first position, the needle distaltip sealingly engages the nozzle seat. In this configuration, the spraygun is closed. When the needle is in a refracted, second position, theneedle distal tip is fully spaced from the nozzle seat. In thisconfiguration, the spray gun is open. The distance between the needleand the seat is identified as the “needle lift.” Further, and asdescribed below, the needle may also be placed anywhere between thefirst and second position, thereby causing the nozzle to be partiallyopen. That is, when the needle is in the second position, i.e., fullyspaced from the nozzle internal passage, the nozzle is, essentially,unblocked and allows for the nozzle's maximum flow rate. It is notedthat, while in the second position, the needle may be disposed withinthe nozzle internal passage, so long as the nozzle achieves its maximumintended flow rate. If the needle is somewhere between the first andsecond positions, the nozzle is partially open and the liquid flows at arate less than the maximum flow rate.

Typically, such spray guns must be opened and closed both rapidly andintermittently. That is, the nozzle is cyclically opened a brief periodof time, then closed for a brief period of time. This would allow, forexample, a quantity of sealant to be applied to an object while thespray gun is open, then for the object to be moved and replaced whilethe spray gun is closed. This is useful for an automated process orassembly line wherein objects such as, but not limited to, cans orshells are moved through the fluid dispensing system.

Many nozzle assemblies of this design utilize a solenoid to move theneedle between the first and second positions. There are at least twoproblems with such solenoids. First, the solenoids are disposedrelatively close to the nozzles. This is a problem because the currentthat causes the rapid opening and closing of the spray gun also causesthe solenoid to heat up. Because the solenoid is close to the spray gunliquid chamber, the liquid in the chamber may become heated. Further,changes in ambient temperatures may vary greatly. As noted above, theliquids dispensed by such spray guns must be maintained in a verylimited temperature range while in the spray gun liquid chamber. Thus,the heat added to the liquid by the solenoid may raise the liquid abovethe desired temperature. Further, such solenoids typically have only twoconfigurations; when the solenoid is charged, the needle is placed inthe second, fully open position. When the solenoid is not charged, aspring or a similar device returns the needle to the first, closedposition. Thus, there was no means to allow for a partial flow of theliquid.

As shown in U.S. Pat. No. 5,945,160, this later disadvantage wasaddressed by controlling the needle solenoid with two steppingsolenoids, an opening stepping solenoid and a closing stepping solenoid.The stepping solenoid rod was coupled to the needle solenoid and movedthe needle solenoid forward and aft in the spray gun housing. Ratherthan using a charged coil, and possibly a spring, to move a rod forwardand back, a stepping solenoid uses a charge to incrementally move a rodin one direction. That is, each incremental movement was a “step.” Theincremental motion may be achieved by rotating a rod disposed in athreaded bore as opposed to moving the rod axially. That is, a steppingsolenoid may include a fixed threaded bore and the solenoid rod may havea threaded portion engaged therewith. Actuation of the stepping solenoidcoil causes the solenoid rod to rotate a portion of a revolution, i.e.,the increment noted above. This rotation causes the solenoid rod to moveaxially relative to the fixed threaded bore. Thus, the solenoid rod maybe moved incrementally axially. That is, a single actuation of thestepping solenoid coil causes the solenoid rod to rotate over an arc,e.g., 5 degrees. Multiple actuations, therefore, cause the solenoid rodto move over multiple arcs, in this example, arcs of 5 degrees each.Each partial rotation of the rod moves the rod axially relative to thethreaded bore. Thus, the stepping solenoid rod may be “stepped” forward.Use of a second stepping solenoid allows for movement in the otherdirection, i.e., the solenoid rod may be stepped backward. As such, theposition of the needle solenoid in the spray gun housing, and thereforethe position of the needle, could be adjusted.

Such stepping solenoids are useful as the needle lift may be changedduring the use of the spray gun. For example, assume a spray gun isinactive at night. When the spray gun is first used in the morning, itis cold and the heated liquid being applied by the spray gun is notaffected by the spray gun temperature. With the liquid at thistemperature, the needle lift should be 0.035 inch. As the day goes on,the ambient temperature increases, thereby raising the temperature ofthe liquid. By noon, the stored liquid is less viscous and, to achievethe same results as in the morning, the needle lift needs to be reducedto 0.015 inch. This type of adjustment cannot be accomplished withtraditional, non-stepping solenoids. A system having a stepping solenoidcan make such an adjustment.

The stepping solenoids typically respond to an input in the form of apulse. That is, the stepping solenoids are energized, and therefore moveone increment, in response to receiving a single pulse of energy. Thisenergy may be supplied directly to the solenoid coil, or may be used toopen and close a circuit that energizes the solenoid coil. For eachpulse received, the solenoid moves one increment or step. Thus, to movethe solenoid rod and needle a selected distance, e.g., 0.015 inch, thestepping solenoid would have to receive thirty pulses. The actuatorcontrol system records the number of pulses sent to each steppingsolenoid thereby tracking the position of the needle.

While this type of spray gun allowed for greater control of the liquidflow rate, i.e., by allowing the needle to be placed in multiplepartially open configurations, another problem developed; the needle wasnot always where the actuator control system “believed” it to be. Thatis, the actuator control system's record of where the needle waspositioned was not always accurate. The actuator control system includesa memory and a processor, hereinafter a programmable logic circuit(PLC), or similar device structured to execute a series of instructions.The memory includes the instructions for the PLC, typically stored in“modules,” as well as data stored in a register. Some of the stored dataincludes data representing the “virtual” needle position. That is, avirtual needle position module correlates the change in needle positionwith the recorded number of pulses sent to each stepping solenoid.Alternatively, the data could be compiled in a “virtual” needle positiondatabase that correlates a number of pulses with a virtual needleposition, e.g.:

Needle Lift in Inches Number of Pulses (Virtual Needle Position) 10.0005 2 0.0010 3 0.0015 4 0.0020 5 0.0025Thus, rather than calculating the needle position, the virtual needleposition module could just record the type (i.e., forward or backwardmotion) and number of pulses sent and then look up the correspondingvirtual needle position.

For example, assume the virtual needle position module correlates eachpulse with a needle lift of 0.0005 in. Further, assume the needle startsin the first position. If the opening stepping solenoid was sent thirtypulses and the closing stepping solenoid 100A was sent fifteen pulses,the needle position module would record the needle as having a needlelift of 0.0075 in. That is, a movement of 0.0005*30=0.015 in. away fromthe needle seat and 0.0005*15=0.0075 toward the needle seat totals aneedle lift of 0.0075 in. The recorded needle position is identified as“virtual” as the actuator control system cannot verify that the needleis actually 0.0075 in. from the nozzle seat. In fact, many times theneedle does not have a needle lift matching the “virtual” needleposition.

This offset between the virtual needle position and the actual needleposition was caused by various factors. For example, the manufacturingtolerances of the various spray gun components is in the range of about+/−0.0001 to +/−0.0005 inch. Thus, during assembly of the gun, thestacking of tolerances may create an error as to the actual position ofthe needle. Further, the initial measurement of needle lift wasperformed manually, which could also be in error. For example, theoperator could make an error in the actual measurement, an error inentering the manual measurement data, or may even forget to enter thedata into the control PLC. Additionally, the gun may, for many reasons,fail to operate, e.g., advance or retract the needle, in a controlledmanner. Thus, either from the initial usage or developing over time, thevirtual needle position and the actual needle position may not be thesame. This is a disadvantage as movement of the needle is based upon thedata representing the virtual needle position.

Manufacturers of spray guns recommend that regular maintenance beperformed on the spray gun nozzles to recalibrate the needle lift. Thisoperation typically requires that the spray gun be taken offline so thatthe actual needle lift may be measured. This data is then incorporatedinto the virtual needle position database. This procedure is timeconsuming, requires an expensive external calibration device, andrequires cleaning the spray gun to remove the sealant. As such, usershave been known to recalibrate a spray gun by unapproved methods such asforcing the needle forward and resetting the virtual position. That is,the users actuate the closing stepping solenoid for a period causing theneedle to move forward. After a short, but indeterminate period of time,the needle engages the seat. As the user does not know when this occursexactly, the user typically allows the closing stepping solenoid tocontinue operating. This continued forward motion of the needle maycause damage to the needle, the nozzle seat, and the closing steppingsolenoid. Once, the user stops the closing stepping solenoid, thevirtual needle position database is updated to indicate that the currentneedle position is in the first position.

SUMMARY OF THE INVENTION

The disclosed and claimed concept provides for a system and method forcalibrating needle lift in a spray gun assembly. The system includes theactuator control system having a user input device, a processor andmemory as well as an actuator sensor structured to detect changes in thecurrent in at least one actuator line conductor and to provide an outputsignal. That is, the at least one actuator line conductor is theconductor that supplies power to the at least one actuator. The actuatorsensor is structured to detect changes in the current characteristicsover time in the at least one actuator line conductor. In the preferredembodiment, the characteristic that is measured is a change ininductance. It is understood, however, the other current characteristicsmay be monitored. More specifically, the at least one actuator has aspecific response when the needle engages the nozzle seat that causes anidentifiable anomaly in the current output signal. When thisidentifiable anomaly is detected, the actuator control system arreststhe forward motion of the needle, i.e., disengages the at least oneactuator. Further, the actuator control system updates the virtualneedle position so as to indicate that the needle's current position isthe closed first position. This operation recalibrates the actualposition of the needle with the virtual position of the needle.

BRIEF DESCRIPTION OF THE DRAWINGS

A full understanding of the invention can be gained from the followingdescription of the preferred embodiments when read in conjunction withthe accompanying drawings in which:

FIG. 1 is a schematic view of a spray gun and actuator control system.

FIG. 2 is a flow chart showing the steps of the method associated withuse of the spray gun.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

As used herein, and when used in reference to communicating data or asignal, “in electronic communication” includes both hardline andwireless forms of communication. It is further understood that “inelectronic communication” includes indirect communication of data andsignals that are converted to different formats so long as theidentified components communicate. For example, if a sensor produces ananalog signal that a modulator converts to a digital format, and thedigital data is communicated to a processor, the sensor and theprocessor are “in electronic communication.”

As used herein, “coupled” means a link between two or more elements,whether direct or indirect, so long as a link occurs.

As used herein, “directly coupled” means that two elements are directlyin contact with each other.

As used herein, “fixedly coupled” or “fixed” means that two componentsare coupled so as to move as one while maintaining a constantorientation relative to each other. The fixed components may, or maynot, be directly coupled.

As used herein, the word “unitary” means a component is created as asingle piece or unit. That is, a component that includes pieces that arecreated separately and then coupled together as a unit is not a“unitary” component or body.

As shown in FIG. 1, a spray gun 10 includes a housing 12 defining anenclosed space 13, and an operating mechanism 14. Preferably, the spraygun housing 12 is elongated and has a longitudinal axis 16. The spraygun housing 12 defines at least a fluid chamber 20 and preferablydefines an operating mechanism chamber 68 as well. The fluid chamber 20and the operating mechanism chamber 68 are sealed from each other sothat no fluid may pass from the fluid chamber 20 to the operatingmechanism chamber 68. The fluid chamber 20 has a fluid inlet 22 and anozzle 26. Further, the fluid chamber 20 may have an excess fluid outlet24. The fluid inlet 22 and the excess fluid outlet 24 are each coupledto, and in fluid communication with, a liquid productdelivery/circulation system 18. The liquid product delivery/circulationsystem 18 delivers a liquid product to the fluid chamber 20 via thefluid inlet 22. If there is a need for recirculation of the liquid, theexcess liquid product exits the fluid chamber 20 via the excess fluidoutlet 24.

The nozzle 26 defines a passage 28 that is in fluid communication withthe fluid chamber 20 and the space outside of the spray gun housing 12.That is, the nozzle passage 28 terminates at an opening 30. Preferably,the nozzle 26 has a body 32 with a generally frusto-conical shape.Further, the nozzle passage 28, or the portion of the nozzle passage 28immediately adjacent the nozzle opening 30, also may have afrusto-conical shape. The nozzle passage 28 about the nozzle opening 30defines a needle seat 34. The needle seat 34 is structured to besealingly engaged with the needle body distal end 64 as described below.

In this configuration, the liquid product may flow into the fluidchamber 20 via the fluid inlet 22. The liquid product, or a portionthereof, may pass through the nozzle 26 and be applied to a work piece(not shown). Again, if there is a need for recirculation of the liquid,the remainder of the liquid product exits the fluid chamber 20 via theexcess fluid outlet 24 and may be re-circulated.

The operating mechanism 14 has at least two electrically poweredactuators 36, 40, a needle 42 and an actuator control system 44. It isnoted that actuator control system 44 and related components, such as,but not limited to, modules, memory, and PLCs, are all shownschematically. Further, actuator control system 44 is shown as anexternal unit. That is, actuator control system 44 is shown outside ofthe solenoid housing 52. It is understood that actuator control system44 may be disposed inside or outside, or partially inside, the solenoidhousing 52 or the spray gun housing 12. It is further noted thatactuator control system 44 is shown as a single unit. As is known,however, the actuator control system 44 may be several elements, eachdisposed in separate locations. For example, a system 80 for calibratingneedle lift and an actuator sensor 82, each described below and each ofwhich are part of the actuator control system 44, are shown as beingincorporated into amplifier 50 (described below).

Each of the at least two actuators 36, 40 has a line conductor 46 (shownschematically) structured to be in electrical communication with a powersource (not shown). The at least two actuators 36, 40 include a solenoid38 and, preferably, a stepping solenoid assembly 100. As is known, asolenoid 38 includes a housing 52, a spring 51, and a coil assembly 54disposed about a solenoid rod 56. The solenoid rod 56 is a magneticmember that is movably, i.e., slidably, coupled to the solenoid housing52 and extends partially therein. The solenoid spring 51 biases thesolenoid rod 56 to an extended, first position, i.e., the solenoid rod56 is substantially out of the solenoid housing 52. The axis of thesolenoid rod 56 is substantially disposed on the housing longitudinalaxis 16. The solenoid coil assembly 54 is disposed within the solenoidhousing 52 and is partially disposed about, but not directly coupled to,the solenoid rod 56. Energizing the coil assembly 54 creates a magneticfield that draws the solenoid rod 56, partially, into the housing 52;this is the withdrawn, second position of the solenoid rod 56. Thesolenoid rod 56 moves between a first and second position; the distancethe solenoid rod 56 travels is the “stroke” and is a characteristic ofthe solenoid 38. That is, the stroke generally cannot be changed and isa known distance. When the coil assembly 54 is not energized, thesolenoid spring 51 maintains the solenoid rod 56 in the first position.Further, because the length of the stroke is known, the spray gun 10 maybe placed in an “initial configuration.” As used herein, the “initialconfiguration” of the spray gun 10 is when the solenoid 38 is positionedwithin the spray gun housing 12 so that the needle 42 seals against theneedle seat 34 at the end of the solenoid stroke. That is, the solenoid38 is at substantially the exact distance from the needle seat 34 as thestroke so that the needle distal end 64 (described below) sealinglyengages the needle seat 34 at the end of the solenoid stroke. It isnoted that, if the solenoid 38 is too close to the needle seat 34, thespring 51 will bias the needle distal end 64 against the needle seatprior to the end of the stroke.

As shown, the solenoid 38 may include an actuator member 58 disposedabout the solenoid rod 56. The solenoid actuator member 58 is made froma material that is attracted to magnetic fields. The solenoid actuatormember 58 acts as a mass capable of being influenced by a magneticfield. Thus, when the coil assembly 54 is energized, there is a strongmagnetic influence on the solenoid actuator member 58 and solenoid rod56 that draws the solenoid rod 56 into the solenoid housing 52. Further,the solenoid actuator member 58 extends partially into the solenoidhousing 52. The solenoid actuator member 58 has an inner end 57 withinthe solenoid housing 52. Between the solenoid actuator member inner end57 and other elements of the solenoid 38 is a spacing device, which istypically a washer, hereinafter the solenoid washer 55. When thesolenoid 38 is energized, the solenoid actuator member 58 is drawn intothe solenoid housing 52 until the solenoid actuator member 58 engagesthe solenoid washer 55. That is, the solenoid actuator member 58 bottomsout against the solenoid washer 55. This engagement limits the length oftravel, i.e., the stroke, of the solenoid rod 56. That is, once theactuator member 58 bottoms out against the solenoid washer 55, theactuator member 58, and therefore the solenoid rod 56, has moved themaximum distance into the solenoid housing 52. Further, the solenoidactuator member 58 may include a flange 59 structured to engage, i.e.,contact, the solenoid housing 52. As discussed in detail below, theentire solenoid 38 is movably disposed in the spray gun housing 12.Further, the solenoid housing 52 may include a threaded coupling 122,located adjacent to the stepping solenoid 100.

The needle 42 has an elongated body 60 having a proximal end 62 and adistal end 64. The needle proximal end 62 is coupled to the solenoid rod56. The needle distal end 64 is shaped to correspond to the shape of theneedle seat 34. Preferably, the needle distal end 64 is conical. Theneedle distal end 64 is disposed adjacent to the needle seat 34. It isnoted that the frusto-conical shape of the nozzle 26 and the needle 42are preferred, but not required. As is known, the needle 42 may have aspherical member (not shown) at the distal end and the nozzle opening 30may have an annular seat (not shown) disposed thereabout. In thisconfiguration, the needle 42 moves axially with the solenoid rod 56substantially along the housing longitudinal axis 16. The distance theneedle 42 moves is equivalent to the stroke of the solenoid rod 56.

Thus, in this configuration, the needle 42 moves between a first, closedposition, wherein the solenoid rod 56 is being biased toward the nozzle26 by the solenoid spring 51, and a second, open position, wherein thesolenoid rod 56 has been drawn away from the nozzle 26 by energizing thecoil assembly 54. When the needle 42 is in the first, closed position,the needle body distal end 64 sealingly engages the nozzle seat 34.Further, as the stroke of solenoid 38 is known, the distance of needlebody 60 travels is a fixed distance. Thus, but for manufacturing errors,thermal expansion, and other factors, the “needle lift,” i.e., thedistance between the needle distal end 64 and the needle seat 34 whenthe needle body 60 is in the second position is fixed. As discussedbelow, however, the actual needle position may be difficult to track.

Further, it is noted that rotation of the solenoid 38 may be preventedby various known methods such as, but not limited to, providing a keyedshape or having an anti-rotation lug (not shown). For example, thesolenoid housing 52 and the interior of the spray gun housing 12 mayhave a cross-sectional shape that is other than circular; in thisconfiguration the elements are “keyed” in that they may not rotaterelative to each other. Alternatively, a lug (not shown) may extend fromthe inner surface of the operating mechanism chamber 68 into thesolenoid housing 52. In this configuration, solenoid 38 may move axiallyin the spray gun housing 12, but not rotate.

A stepping solenoid assembly 100 operates in a slightly differentmanner. That is, a stepping solenoid assembly 100 is structured to causea solenoid rod 106, or an actuator fixed to the solenoid rod 106, torotate. A stepping solenoid 100 also has a housing 102, and a coilassembly 104 disposed about a rotatable solenoid rod 106. It isunderstood that an actuator (not shown) may be fixed to the rotatablesolenoid rod 106. One type of stepping solenoid assembly 100 includes acoil assembly 104 and solenoid rod 106 each having a number of radialpeaks (not shown) or similar structure, disposed about their inner andouter circumference, respectively. The inwardly extending radialelements extend to a point close to, but not in contact with, the tipsof a sprocket (not shown) fixed to the solenoid rod 106. The coilassembly 104 includes at least two, and typically three, separate coils(not shown) of wire, each capable of being independently energized. Theseparate coils are each coupled to alternate, or more typicallysequential and repeating sets of, inwardly extending radial elements,e.g., one set of radial elements are associated with each coil. In thisconfiguration, the magnetic force created when one coil in the steppingsolenoid coil assembly 104 is energized is concentrated in theassociated set of the extending radial elements. This magnetic forcecauses the tips of the stepping solenoid sprocket to move toward thatset of inwardly extending radial elements. When the next coil isenergized, the next set of inwardly extending radial elements becomemagnetic and draws the tips of the stepping solenoid sprocket to movetoward that set of inwardly extending radial elements. By sequentiallyenergizing the coils, the magnetic effect on the stepping solenoidsprocket causes the stepping solenoid rod 106 to rotate.

Alternatively, the stepping solenoid rod 106 may move axially, but becoupled to a disk (not shown) having one or more arcuate races (notshown) therein. The races are shallow at one end and deeper at theother. A bearing (not shown), such as but not limited to a ball bearing,is disposed in the race. The disk is disposed adjacent to the steppingsolenoid housing 102. When the stepping solenoid assembly 100 isactuated, the disk is drawn toward the stepping solenoid housing 102;this causes the bearings to move into the deeper portion of the raceswhich, in turn, causes the disk to rotate; that is, the bearingsactually maintain a generally stationary position relative to travel inthe stepping solenoid housing 102, but, as the bearings are biasedtoward the deeper part of the arcuate races, the disk rotatespositioning a deeper part of the races over the bearings. A ratchet, orsimilar construct, (not shown) disposed between the stepping solenoidrod 106 and the disk is used to prevent counter-rotation when thestepping solenoid assembly 100 is de-energized.

These types of stepping solenoid assemblies 100 are exemplary and thisdisclosure is not limited to any specific type of stepping solenoidassembly 100. Any stepping solenoid assembly 100, however, is structuredto cause a stepping solenoid rod 106 to rotate over an arc when the coilassembly 104 is energized.

Preferably, the stepping solenoid assembly 100 includes two steppingsolenoids, i.e., a first and second stepping solenoid 100A, 100B, havinga common solenoid rod 106. Preferably, the stepping solenoid rod 106 issubstantially aligned with the spray gun housing 12 longitudinal axis 16and nozzle opening 30. The two stepping solenoids 100A, 100B may alsoshare a housing 102. The first stepping solenoid coil assembly 104A isstructured to cause the common solenoid rod 106 to rotate in a firstdirection and the second stepping solenoid coil assembly 104B isstructured to cause the common solenoid rod 106 to rotate in a seconddirection. Thus, the stepping solenoid assembly 100 is bi-directional,i.e., structured to rotate the stepping solenoid rod 106 in twodirections. In an alternate embodiment, a single stepping solenoidassembly 100 is a bi-directional stepping solenoid assembly 100. Forexample, a stepping solenoid assembly 100 may be structured so thatcurrent may be passed in two directions through the coil assembly 104thereby causing the stepping solenoid rod 106 to rotate in a directionassociated with the direction of the current.

If the stepping solenoid assembly 100 is the type wherein the steppingsolenoid rod 106 only rotates, i.e., the embodiment wherein arcuateraces are not used, the stepping solenoid rod distal end 120 may bethreaded, i.e. the end of the stepping solenoid rod 106 extending out ofthe stepping solenoid housing 102 may be threaded. The stepping solenoidrod threaded distal end 120 is structured to thread into the solenoidhousing threaded coupling 122. As noted above, the solenoid 38 ismovably disposed in the spray gun housing 12 but also prevented fromrotating. That is, the solenoid 38 is structured to slide axially in thespray gun housing 12. In this configuration, the stepping solenoid rod106 rotates but does not move axially and the solenoid 38 is structuredto slide axially but not rotate. Thus, when stepping solenoid rodthreaded distal end 120 rotates in solenoid housing threaded coupling122, to cause the solenoid 38 to move axially.

If stepping solenoid assembly 100 has a disk-like actuator, i.e., astepping solenoid assembly 100 wherein the stepping solenoid rod 106moves axially as well as rotates, the stepping solenoid rod distal end120 may be pinned to solenoid 38. That is, solenoid 38 and steppingsolenoid rod distal end 120 are structured to abut each other, orotherwise maintain a fixed spacing. The coupling between solenoid 38 andstepping solenoid rod distal end 120, however, allows stepping solenoidrod 106 to rotate. It is again noted that solenoid 38 is structured toslide axially but not rotate. Thus, in this configuration, actuation ofthe stepping solenoid assembly 100 causes solenoid 38 to move axially asstepping solenoid rod 106 moves axially.

Thus, actuation of the stepping solenoid 100 causes the entire solenoid38 to move forward or backward in the operating mechanism chamber 68,thereby allowing adjustment and/or recalibration of the needle 42position. That is, actuation of the first or second stepping solenoid100A, 100B causes the stepping solenoid rod 106 to rotate in onedirection. As the stepping solenoid rod 106 is coupled to the solenoid38, either threadably or in a fixed relationship, and because thesolenoid 38 is non-rotatably, but slidably, disposed in the spray gunhousing 12, actuation of the first or second stepping solenoid 100A,100B causes the solenoid 38 to slide within the spray gun housing 12.Moreover, the solenoid 38 moves over a path generally aligned with thehousing axis 16. For the purpose of this application, it is assumed thatactuation of the first stepping solenoid 100A causes the solenoid 38 tomove away from the nozzle 26 and actuation of the second steppingsolenoid 100B causes the solenoid 38 to move toward the nozzle 26. Asthe needle body 60 is coupled to the solenoid 38, adjusting the positionof the solenoid 38 also adjusts the position of the needle body 60.

Preferably, a charge is applied to the stepping solenoid coil assembly104, in pulses. For each pulse, the solenoid rod 56 rotates a discreteincrement or “step.” Thus, the stepping solenoid rod 106 moves indiscrete increments or “steps.” It is noted that the axial distance thatthe solenoid rod 56 moves may be controlled by adjusting the pitch ofthe threads in the solenoid housing threaded coupling 122. In thepreferred embodiment, the solenoid rod 56 moves axially between about0.001 and 0.0005 inch per step and, more preferably, about 0.0005 inchper step. Further, it is noted that the pulses may be provided to thestepping solenoid coil assembly 104 directly from the actuator controlsystem 44 via the at least one actuator line conductor 46, meaning thatthe actuator control system 44 is the power source, or, the at least oneactuator line conductor 46 may be coupled to a power system (not shown)and the actuator control system 44 may control a switch (not shown)disposed between the power system and the at least one actuator lineconductor 46. Preferably, there is an amplifier 50, which is part of theactuator control system 44, which is disposed between the steppingsolenoid coil assemblies 104A, 104B and other parts of the controlsystem 44, such as the PLC 48 (discussed below). Further, as discussedbelow, the amplifier 50 includes a control system having at least amemory 47.

Further, and depending upon which stepping solenoid 100A, 100B isactuated, the pulses may be said to have an associated “direction.” Thatis, the pulses may cause the solenoid 38, and therefore the needle body60, to move away from the nozzle opening 30 or toward the nozzle opening30. As used herein, an “opening pulse” is a pulse that actuates theopening stepping solenoid 100A. Conversely, a “closing pulse” is a pulsethat actuates the closing stepping solenoid 100B causing the solenoid 38to move toward the nozzle opening 30.

Thus, the solenoid 38 is structured to receive input commands from theactuator control system 44 and to move the needle 42 between the firstposition and a selected position, or the second position, while thestepping solenoid assembly 100 is structured to receive input commandsfrom the actuator control system 44 and to incrementally move the needle42 in response to the commands.

That is, the stepping solenoid assembly 100 moves the solenoid 38 withinthe spray gun housing 12 which, in turn, moves the needle 42. Thus, thestepping solenoid assembly 100 is structured to provide fine adjustmentto the needle 42 position. The actuator control system 44 includes oneor more PLCs 48 and memory 49. Hereinafter, “PLC” shall mean one or morePLCs 48. The memory 49 includes random access memory (data can berecorded and read) and read only memory (data can be read only) and maybe physically embodied by any known memory device such as, but notlimited to, integrated circuits (computer chips), flash memory, magneticmemory, optical memory, or disk based memory (CD, DVD, hard drives,etc.). The PLC 48 and memory 49 are in electronic communication witheach other.

It is noted that elements of the actuator control system 44 are shownschematically as being separate from the spray gun housing 12 andgrouped together for clarity. As is known, however, the elements of theactuator control system 44 may be disposed in, or on, the spray gunhousing 12 and may not be grouped together as shown. For example,elements of the actuator control system 44 may be positioned so as toreduce electronic noise and interference. Thus, the claims are notlimited to the schematic configuration of the actuator control system 44as shown. For example, the amplifier 50 is, preferably, disposed in thespray gun housing 12, and more preferably at the end of the spray gunhousing opposite the nozzle 26. This end of the spray gun housing 12 mayinclude a communication port or coupling 45.

The operation of a PLC 48 is beyond the scope of this document, however,as is known, a PLC 48 is structured to execute a series of instructions,to receive input, and to provide output. As used herein, the series ofinstructions are contained in one or more “modules” that areincorporated in the PLC 48 or stored in an associated memory 49. The PLC48 is structured to read and execute one or more modules substantiallysimultaneously. Further, it is understood that the actuator controlsystem 44 includes components, such as, but not limited to, one or moretimers structured to track or measure time, modulators/demodulators forconverting digital signals to analog signals and vice versa, generatingvideo signals or other output signals, etc., that enable the actuatorcontrol system 44 to accomplish any function the actuator control system44 is structured to perform. Again, the details of how a PLC 48 performsthese functions is beyond the scope of this document but are known inthe art. Further, it is understood that the actuator control system 44includes any conductors, connectors, etc., that are required to allowthe various components to communicate with each other. For example, theactuator control system 44 is disposed adjacent to the amplifier 50 andthere is a conductor (not shown) extending therebetween. Similarly,there are conductors (not shown) extending between the amplifier 50 andboth the solenoid 38 and the stepping solenoids 100A, 100B.

The actuator control system 44, preferably, further includes a remoteuser interface 70, a user interface module 72, an actuator controlmodule 74, and a needle position module 76. Typically, the userinterface module 72, actuator control module 74, and needle positionmodule 76 (modules shown schematically) are stored in the actuatorcontrol system memory 49 and are loaded into the PLC 48 as needed.Alternately, one or more of the modules 72, 74, 76 may be permanentlyincorporated into the PLC 48. The remote user interface 70 is aninterface presented in a manner that may be used by a user. The remoteuser interface 70 may be presented on any known interface such as, butnot limited to, a touch screen, a monitor and keyboard, or, an analogdisplay and manual input devices, e.g., knobs, buttons, switches, etc.,so long as the remote user interface 70 allows a user to input a desiredneedle lift, initiate use of the spray gun 10, terminate use of thespray gun 10, and recalibrate the needle lift, as described below. Theuser interface module 72 is structured to receive input from a user viathe user interface 70 and to communicate that input to the actuatorcontrol module 74.

The actuator control module 74 receives input from the user interfacemodule 72 and is structured to put into effect the user's input. Theactuator control module 74 cooperates, and communicates, with the needleposition module 76 so as to move the needle 42 in accordance with theuser input. Thus, for example, the user may cause the solenoid 38 toopen and close in a specific pattern. Moreover, the actuator controlsystem 44 in conjunction with the stepping solenoids 100A, 100B may beused to make fine adjustments to the needle position or recalibrate theneedle position. This is accomplished by actuating the steppingsolenoids 100A, 100B to mechanically move the solenoid 38 toward or awayfrom the nozzle 26, as described above. The mechanical movement of thesolenoid 38, i.e., the position of the solenoid 38, and therefore theneedle body 60, is tracked by the actuator control system 44.

More specifically, the actuator control system memory 49, and/or theamplifier memory 47, in conjunction with, or as part of, the needleposition module 76, are utilized as registers to track the number anddirection of the pulses sent to the stepping solenoids 100A, 100B and/orthe position of solenoid 38. It is assumed that the needle 42 alwaysstarts operation in the first position, i.e., closed. That is, thesolenoid 38 is in the first position and the needle body distal end 64is engaging the needle seat 34. When there is a need to make a fineadjustment to the needle body 60 position, the actuator control system44 sends a number of pulses, or sends a command or signal to a switchthat, in turn, sends a number pulses to the at least one actuator 40causing the needle 42 to move as described above. These pulses may bepassed through the amplifier 50. Each pulse and its associated directionis recorded in the needle position module registers 77 within theactuator control system memory 49 and the amplifier memory 47, asdiscussed below.

For example, during the day, ambient temperatures increase and theviscosity of the fluid may decrease. To ensure the proper amount ofliquid is applied, the needle position must be adjusted. In thisexample, the solenoid 38 needs to be moved forward, i.e., toward thenozzle seat 34, thereby reducing the needle lift when the needle body 60is in the second position. Before this operation may be accomplishedautomatically, it may be done manually to determine the amount ofadjustment needed. Thus, the solenoid 38 is energized and the needlelift is measured. In this example, the needle lift is assumed to be toogreat, i.e., the needle body 60 is too far from the needle seat 34 whenin the second position, so the closing stepping solenoid 100B isactuated. This causes the solenoid 38 to be moved toward the nozzle seat34 as described above. The distance that the solenoid 38 needs to bemoved may be determined by a manual measurement. After such data isrecorded over a period of time, the distance may be selected as theaverage distance the solenoid 38 is typically moved. Thus, in thisexample, a user would adjust the needle position forward every day at acertain time or once the ambient temperature reached a selected mark.Further, the amount of adjustment is recorded in the needle positionmodule registers 77. Thus, if the needle position, i.e., the position ofthe solenoid 38, needed to be reset to the original position, the usermerely has to move the solenoid 38 toward the nozzle seat 34 by the samedistance, i.e., the same number of pulses but in the opposite direction.

This system may also be used to calibrate the needle position. Beforediscussing the calibration process, it is noted that the physicalelements of the spray gun 10 have known characteristics, such as, butnot limited to, dimensions, which do not change. Thus, if the elementsof the spray gun 10 are placed in a selected configuration wherein theactual needle position is known, then the actuator control system 44 maybe calibrated to this known position. Accordingly, the spray gun 10 hasa “calibration configuration” wherein the elements identified below areplaced in a specific configuration. The “calibration configuration” isachieved by performing the following steps. First, the closing steppingsolenoid 100B is actuated. This causes the solenoid 38 to be movedtoward the needle seat 34 as described above. As the solenoid 38 ismoved toward the needle seat 34, the solenoid actuator member 58, andmore preferably the solenoid actuator member flange 59, engages thespray gun housing 12. When this occurs, the solenoid actuator member 58can no longer move. Continued actuation of the closing stepping solenoid100B causes the solenoid 38 to continue to move toward the needle seat34. The motion of the solenoid 38 causes the solenoid rod 56, andeventually the solenoid actuator member 58, to move into the solenoidhousing 52. The motion of the solenoid 38 continues until the solenoidactuator member 58 bottoms out against the solenoid washer 55. That is,solenoid 38 is moved forward until the solenoid actuator member 58bottoms out against the solenoid washer 55. At this point, the solenoid38 may not be moved forward anymore. It is further noted that, thesolenoid rod 56 is in the second position while the needle 42 stillengages the nozzle seat 34. Hereinafter, the act of the solenoidactuator member 58 bottoming out against the solenoid washer 55 shall beidentified as “the actuator member 58 seats against the solenoid 38.”

This is the “calibration configuration” as the position of all theelements are known. It is noted that the “initial configuration” and the“calibration configuration” both relate to the configuration of thesolenoid 38 and a stepping solenoid assembly, i.e., stepping solenoids100A, 100B, and their relationship to each other. The actuator controlsystem 44 may be calibrated to this known position. That is, the“virtual needle position,” which is the where the actuator controlsystem 44 “believes” the needle body 60 to be may be set to correspondwith the “actual needle position” that is known when the spray gun 10 isin the “calibration configuration.” Further, the difference between thecalibration configuration and the initial configuration may bedetermined by manual measurement. That is, the actuator control system44 is programmed with a “virtual calibration configuration” that shouldcorrespond to the actual needle position when the spray gun 10 is in thecalibration configuration.

For example, following multiple manual measurements of the configurationof the spray gun 10 in the calibration configuration, it may bedetermined that the solenoid 38 is typically moved forward a distancecorresponding to fifty forward pulses of the closing stepping solenoid100B. Thus, the “virtual calibration configuration” relative to theinitial position may be recorded as fifty forward pulses. Thus, when thespray gun 10 is in the calibration configuration, the needle positionmodule register 77 may be reset to be at fifty forward pulses (in thisexample). Alternatively, the spray gun 10 may be returned to the initialconfiguration following calibration. That is, the actuator controlsystem 44 will cause the opening stepping solenoid 100A to be activatedfifty times. At this point, i.e., after the opening stepping solenoid100A has activated fifty times (in this example) following calibration,spray gun 10 is in the “initial configuration” described above. Further,when the spray gun 10 is in this configuration, the needle positionmodule register 77 may be reset to zero so that the virtual needleposition corresponds to the actual needle position, which is the initialconfiguration. That is, the needle position module register 77 may bereset when the spray gun 10 is in the calibration configuration, whereinthe position of the spray gun 10 element is known, or, the needleposition module register 77 may be reset to zero immediately followingcalibration with the spray gun 10 in the initial configuration. The actof resetting the needle position module register 77 is hereinafteridentified as “zeroing” the needle position module 76. Calibration isrequired, or is at least desirable, when the actual needle position nolonger corresponds to the virtual needle position.

The needle position module 76 is executed in the actuator control system44 and is structured to track the “virtual needle position.” While thistracking may be made relative to any point, for the sake of this exampleit will be assumed that the point of reference is a selected openposition of the needle 42, i.e., when the solenoid 38 is in the secondposition and the needle body distal end 64 is separated from the needleseat 34 by the distance of the solenoid 38 stroke. In thisconfiguration, and when the solenoid 38 is not actuated, needle 42sealingly engages the nozzle seat 34; this is the “zero” configurationor initial configuration for the spray gun 10. Once the spray gun 10 isin the initial configuration, the needle 42 “actual needle position” maybe measured as the distance the needle 42 has moved relative to theneedle in the first position. That is, the “actual needle position” ismeasured when the needle body 60 is in the second position. The “virtualneedle position” reflects the same “virtual” position, but relies uponthe assumption that the movement of the stepping solenoid rod 106, andtherefore the needle 42, is exact.

For the sake of this example, it is assumed that the spray gun isinitially calibrated. That is, the spray gun 10 is in the initialconfiguration and the actual needle position corresponds to the virtualneedle position. Thus, as the solenoid rod 56 has a predeterminedstroke, i.e., a known amount of travel, the needle body 60 secondposition is known as well. Accordingly, at the start-up of the spray gun10, the needle actual position is the first closed position and theamount of needle lift when the needle body 60 is in the second positionis known. Further, the virtual needle position is initially recorded asbeing the first closed position. For this example, the needle positionmodule registers 77 are empty, or the stored values total zero, when thespray gun 10 is in the initial configuration. The needle position module76 may include a database 78 correlating the total value of pulses,i.e., the number of all forward pulses less the number of backwardpulses, to a needle position, i.e., a selected needle lift, such as setforth in the table below.

Needle Lift when in the Second Position, in Inches Number of Pulses(Virtual Needle Position) 0 0.0020 (Needle First Position) 1 0.0025 20.0030 3 0.0035 4 0.0040 5 0.0045Alternatively, the needle position module 76 may be programmed with amultiplier, e.g., every backward pulse equals an additional needle liftof 0.0005 inch. Thus, the needle position module 76 would only need torecord the number of the pulses, and their associated direction(collectively, and as used herein, “needle position data”) in order tosolve for, i.e., determine, the virtual needle position. Alternately,the needle position may be tracked by an encoder or Linear VariableDifferential Transformer (LVDT).

Regardless of whether the needle position module 76 has a database orcalculates the position each time, the needle position module 76 tracksthe number of pulses sent to the at least one actuator 40 as well as thedirection which the needle 42 is moved. For example, if there are twostepping solenoids 100A, 100B, the needle position module 76 tracks thenumber of pulses sent to each stepping solenoids 100A, 100B. Based onthis information, the needle position module 76 may calculate, or lookup, the virtual needle position. Other modules may request this data.

The needle position module 76 records the needle position data in aneedle position module register 77 and this information may also berecorded in an amplifier register 79. The needle position moduleregister 77 may record all, or a portion of, the needle position datasent by the actuator control module 74 to the stepping solenoids 100A,100B. The portion of data recorded may be only the current position ofthe needle 42. Regardless of how much data is recorded, or the type ofdata recorded, the needle position data always includes data indicatingthe current virtual position of the needle 42. For example, and againassuming the needle 42 starts in the first position, the needle positionmodule register 77 may record the needle position data for the last fourinstructions sent to the stepping solenoids 100A, 100B, e.g., sevenforward pulses, five backward pulses, three forward pulses and five morebackward pulses. The needle position module 76 may determine the currentvirtual needle position by summing the number of pulses and multiplyingthe sum by a multiplier, as noted above. In this example, the sum iszero, so the needle position module 76 would determine that the needleis in the position in which it started, i.e., the virtual firstposition. This position should correspond with the needle body distalend 64 having a lift corresponding to the solenoid 38 selected strokewhen the needle body 60 is in the second position. However, due tovarious factors identified above, this may not be true.

As a specific example, assume that the stepping solenoids 100A, 100Bhave each been actuated a number of times so that the position of theneedle body 60 in the second position no longer corresponds to theinitial position. The needle position module register 77 has recordedthe needle position data. Further assume the spray gun 10 operation wasinterrupted by a power outage and the needle position module register 77is reset. Thus, following the interruption, the actual needle positionno longer corresponds to the virtual needle position. That is, asdescribed, the stepping solenoids 100A, 100B have each been actuated anumber of times so that the position of the needle body 60 in the secondposition no longer corresponds to the initial position, but, the needleposition module register 77 is blank, meaning that the data available tothe actuator control system 44 indicates that the needle body 60 is inthe initial position. That is, the actuator control system 44 “believes”that the needle body 60 is in the initial position. When this occurs,the spray gun 10 needs to be recalibrated.

To do this, the spray gun 10 is placed in the calibration configurationdescribed above. That is, closing stepping solenoid 100B is actuateduntil the actuator member 58 seats against the solenoid 38. The virtualneedle position is then reset as the virtual calibration configurationto reflect the actual configuration, or, the spray gun 10 may be placedin the initial configuration and the needle position module 76 zeroed,as described above.

In the example above, the spray gun 10 was placed in the initialconfiguration and the needle position module register 77 was zeroed,thereby bringing the actual needle position and the virtual needleposition into accord. This process may be accomplished by the spray gun10 automatically as described hereinafter. The actuator control system44 may further include a system 80 for calibrating needle lift. Theneedle lift calibration system 80 includes an actuator sensor 82, acalibration module 84, and the needle position module 76 describedabove. The actuator sensor 82 is structured to detect changes incharacteristics of the characteristics of the current in the at leastone actuator line conductor 46 and to provide an output signal. In thepreferred embodiment, the current characteristics that is monitored isthe inductive reactance of the coil as measured by changes in thecurrent, such as changes in current and voltage, but any appropriatecharacteristic may be monitored. The detected change is an “identifiableanomaly” in the characteristic being measured.

That is, the current to the at least one actuator 40 has a number ofcharacteristics such as inductance. The current characteristics havepredictable changes. For example, when the at least one actuator 40 isbeing used to advance the needle 42, the inductance of the current maybe measured and, if displayed, may be seen as an identifiable and knownwave. Further, the current characteristics may also reflect randomchanges, generally identified as “noise.” The noise may be detected and,if displayed, may be seen as anomalies in a regular pattern. There are,however, “identifiable anomalies” that are produced as a result of aspecific action.

For example, if the closing stepping solenoid 100B is advancing, i.e.,moving the solenoid 38 forward and the actuator member 58 seats againstthe solenoid 38, as described above, there is a mechanical feedback fromthe closing stepping solenoid 100B. This feedback to the closingstepping solenoid 100B produces an anomaly in the characteristics of thecurrent and voltage in the at least one actuator line conductor 46.Moreover, this anomaly, or a substantially similar anomaly, occurs eachtime the actuator member 58 seats against the solenoid 38 while theclosing stepping solenoid 100B is advancing. This specific anomaly onlyoccurs when the spray gun 10 is in the calibration configuration. Assuch, this anomaly is an “identifiable anomaly” that is different fromthe normal characteristics of the current in the at least one actuatorline conductor 46 as well as different from the characteristics ofrandom noise. Accordingly, as used herein, an “identifiable anomaly” isan anomaly in the current and voltage in the at least one actuator lineconductor 46 that has been associated with a known physical condition,configuration, or state of a stepping solenoids 100A, 100B. Morespecifically, a “solenoid seating anomaly” is an anomaly current in theat least one actuator line conductor 46 that has been determined tooccur when the actuator member 58 seats against the solenoid 38.Generally, an anomaly becomes associated with a condition based onexperimentation and verifying that a specific, distinct anomaly occurseach time the stepping solenoids 100A, 100B are placed in a specificphysical condition, configuration, or state. Preferably, theidentifiable anomaly associated with the actuator member 58 seatingagainst the solenoid 38 is a change in inductance identified by changesin current and voltage.

It is noted that the current characteristics have been identified asbeing measurable and displayed in the form of a wave. While a monitor(not shown) may be provided and the wave displayed, this is notrequired. That is, as is known, the actuator control system 44 may bestructured to detect the wave and any anomalies without actuallycreating a visual image of the wave and/or anomaly.

The calibration module 84 is a set of instructions structured to beexecuted by the actuator control system 44 and, more specifically byactuator control system PLC 48. As with the description of the PLC 48,it is beyond the scope of this document to describe in detail how amodule interacts with the PLC 48, however, as is known, the module 84 isexecuted with the PLC 48 and may be described as performing, or as beingstructured to perform, selected operations and functions. Thus, asdescribed above, the needle position module 76 is structured to trackthe “virtual” position of the needle 42. The calibration module 84 is,preferably, executed infrequently. For example, the calibration module84 may be executed based on a period of time, e.g., every two weeks, or,after a certain number of operations, e.g., every 2 million actuationsof the stepping solenoids 100A, 100B. The calibration module 84 isstructured to reset the virtual needle position, i.e., zero the needleposition module 76, to reflect the actual needle position. Preferably,the calibration module 84 clears all data in the needle position moduleregister 77. Alternately, the calibration module 84 may update the lastentry in the needle position module register 77 so as to indicate thespray gun 10 as being in the initial configuration. That is, whenoperation of the spray gun 10 is initiated, the spray gun is in theinitial configuration. As the stepping solenoids 100A, 100B areutilized, the needle position module 76 records the virtual needleposition data, as described above. Over time, the virtual needleposition no longer corresponds to the actual needle position and theneedle position must be calibrated. This is accomplished by executingthe calibration module 84 which first places the solenoid 38 in thecalibration configuration.

During this operation, the calibration module 84 monitors the at leastone actuator line conductor 46 for an identifiable anomaly indicatingthat the actuator member 58 has seated against the solenoid 38. When theidentifiable anomaly is detected, the forward motion of the closingstepping solenoid 100B is arrested and the calibration module 84 returnsthe spray gun 10 to the initial configuration, as described above, andzeros the needle position module 76 so that the needle position module76 identifies the current spray gun configuration as the initialconfiguration. At this point, the needle 42 position is calibrated andthe spray gun 10 may be returned to normal operations. It is noted that,unlike prior manual calibration methods, this may be accomplished whilethe fluid chamber 20 is filled with liquid product. That is, thecalibration module 84 is operable when the fluid chamber 20 is filledwith fluid.

The at least two actuators, 36, 40 and the actuator control system 44are, preferably, substantially disposed in the operating mechanismchamber 68. That is, portions of the at least one actuator 40 and theactuator control system 44 may extend beyond the operating mechanismchamber 68. For example, the solenoid rod 56 and/or the needle 42extends from the operating mechanism chamber 68 into the fluid chamber20. The bulk of the at least one actuator 40 and the actuator controlsystem 44 are, however, disposed in the operating mechanism chamber 68.Further, the actuator sensor 82 is disposed entirely within theoperating mechanism chamber 68, and is preferably part of amplifier 50.In this configuration, the spray gun 10 is not coupled to an externalcontrol system. It is noted that the actuator control system 44 and theactuator sensor 82 are disposed close to the stepping solenoid assembly100 so as to reduce the “noise” in the conductors that may interferewith detecting an identifiable anomaly.

Accordingly, and using the components described above, a method ofcalibrating needle lift in a spray gun 10 includes the following steps:placing 200 the spray gun 10 in a calibration configuration, monitoring202 the current in the stepping solenoid assembly 100 having a lineconductor 46, detecting 204 an identifiable anomaly in the current'scharacteristics, placing 205 the spray gun 10 in an initialconfiguration, and zeroing 206 the needle position module 76.

As noted above, the needle position module 76 is structured to record anumber of pulses sent to the stepping solenoid assembly 100. Thus, thestep of zeroing 206 the needle position module 76 so as to record thespray gun 10 configuration as the initial configuration may include thestep of changing 212 the total value of recorded pulses to zero. Thischange may be accomplished by adding a number of pulses, with anassociated direction, to the recorded needle position data so that thesum of the needle position data equals zero. Alternatively, the step ofzeroing 206 the needle position module 76 so as to record the spray gun10 configuration as the initial configuration may include the step ofclearing 214 the needle position module register 77, wherein “clearing”means deleting all entries in the needle position module register 77.Further, as noted above, the four steps of the calibration 200, 202,204, and 206, may occur when the fluid chamber 20 is filled with aliquid.

While specific embodiments of the invention have been described indetail, it will be appreciated by those skilled in the art that variousmodifications and alternatives to those details could be developed inlight of the overall teachings of the disclosure. Accordingly, theparticular arrangements disclosed are meant to be illustrative only andnot limiting as to the scope of invention which is to be given the fullbreadth of the claims appended and any and all equivalents thereof.

What is claimed is:
 1. A system for calibrating needle lift in a spraygun assembly, said spray gun assembly having an operating mechanism anda nozzle, said nozzle having an opening and a needle seat disposed aboutthe inner surface of said nozzle opening, said operating mechanismhaving a solenoid, a stepping solenoid assembly, a needle and anactuator control system, said solenoid including a line conductor and anactuator member, said stepping solenoid assembly having a line conductorsaid actuator control system structured to control said steppingsolenoid assembly to provide fine adjustment to said needle position,said solenoid and said stepping solenoid assembly having an initialconfiguration and a calibration configuration, said system forcalibrating needle lift comprising: an actuator sensor structured todetect changes in the current in at least one actuator line conductorand to provide an output signal; a calibration module being executed insaid actuator control system, said calibration module structured toreceive said actuator sensor output signal; and said calibration modulefurther structured to detect an identifiable anomaly in said sensoroutput signal, said identifiable anomaly indicative of said actuatormember being in a known position.
 2. The system for calibrating needlelift in a spray gun assembly of claim 1 wherein: said known position isthe position wherein said actuator member seats against said solenoid;and in response to detecting said identifiable anomaly, recording needlevirtual position data indicating that the current position of saidneedle corresponds to the spray gun calibration configuration.
 3. Thesystem for calibrating needle lift in a spray gun assembly of claim 1wherein said identifiable anomaly is a change in a currentcharacteristic.
 4. The system for calibrating needle lift in a spray gunassembly of claim 1 wherein said identifiable anomaly is a solenoidseating anomaly.
 5. The system for calibrating needle lift in a spraygun assembly of claim 1 further including: a needle position modulebeing executed in said actuator control system, said needle positionmodule structured to track the virtual position of said needle; andwherein, upon detection of an identifiable anomaly, said needle positionmodule is zeroed.
 6. The system for calibrating needle lift in a spraygun assembly of claim 5 wherein said calibration module is structured toreturn said solenoid and said stepping solenoid to said initialconfiguration upon detection of an identifiable anomaly.
 7. The systemfor calibrating needle lift in a spray gun assembly of claim 1 whereinsaid calibration module is structured to return said solenoid and saidstepping solenoid to said initial configuration upon detection of anidentifiable anomaly.
 8. The system for calibrating needle lift in aspray gun assembly of claim 1 wherein said spray gun includes a housing,said housing defines a fluid chamber, and, wherein said calibrationmodule is operable when said fluid chamber is filled with fluid.
 9. Thesystem for calibrating needle lift in a spray gun assembly of claim 1wherein said actuator sensor is incorporated into an amplifier.
 10. Aspray gun assembly having a system for calibrating needle liftcomprising: a nozzle having an opening and a needle seat disposed aboutthe inner surface of said nozzle opening; an operating mechanism havinga solenoid, a stepping solenoid assembly, a needle and an actuatorcontrol system; said solenoid having a movable actuator member coupledto said needle and being structured to move said needle; said actuatorcontrol system structured to control said solenoid and said steppingsolenoid assembly so as to move said needle between said first positionand a selected position; said solenoid having a line conductor, saidsolenoid structured to receive input commands from said actuator controlsystem and to incrementally move said needle in response to saidcommands; said stepping solenoid assembly having a line conductor, saidstepping solenoid assembly structured to receive input commands fromsaid actuator control system and to incrementally move said needle inresponse to said commands; said needle coupled to said solenoid, saidneedle shaped to sealingly engage said needle seat; said steppingsolenoid assembly coupled to said solenoid via a solenoid spring, andstructured to move said solenoid within said spray gun housing; saidsolenoid and stepping solenoid assembly having an initial configurationand a calibration configuration; a system for calibrating needle liftincluding an actuator sensor and a calibration module; said actuatorsensor structured to detect changes in the current in at least oneactuator line conductor and to provide an output signal; saidcalibration module being executed in said actuator control system, saidcalibration module structured to receive said actuator sensor outputsignal; and said calibration module further structured to detect anidentifiable anomaly in said sensor output signal, said anomalyindicative of said actuator member being in a known position.
 11. Thespray gun assembly of claim 10 wherein: said known position is theposition wherein said actuator member seats against said solenoid; andin response to detecting said identifiable anomaly, recording needlevirtual position data indicating that the current position of saidneedle corresponds to the spray gun calibration configuration.
 12. Thespray gun assembly of claim 10 wherein said identifiable anomaly is achange in a current characteristic.
 13. The spray gun assembly of claim10 wherein said identifiable anomaly is a solenoid seating anomaly. 14.The spray gun assembly of claim 10 further including: a needle positionmodule being executed in said actuator control system, said needleposition module structured to track the virtual position of said needle;and wherein, upon detection of an identifiable anomaly, said needleposition module is zeroed.
 15. The spray gun assembly of claim 14wherein said calibration module is structured to return said solenoidand said stepping solenoid to said initial configuration upon detectionof an identifiable anomaly.
 16. The spray gun assembly of claim 10wherein said calibration module is structured to return said solenoidand said stepping solenoid to said initial configuration upon detectionof an identifiable anomaly.
 17. The spray gun assembly of claim 10wherein said spray gun includes a housing, said housing defines a fluidchamber, and, wherein said calibration module is operable when saidfluid chamber is filled with fluid.
 18. The spray gun assembly of claim10 wherein said actuator sensor is incorporated into an amplifier.
 19. Asystem for calibrating needle lift in a spray gun assembly comprising:an actuator sensor structured to detect changes in a current in one of asolenoid line conductor or a stepping solenoid assembly line conductorand to provide an output signal; a calibration module structured toreceive said actuator sensor output signal; and said calibration modulefurther structured to detect an identifiable anomaly in said sensoroutput signal.
 20. The system for calibrating needle lift in a spray gunassembly of claim 19 wherein said identifiable anomaly is a change in acurrent characteristic.